Download Miller Electric OM-1102 Owner`s manual
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OM-1102 113 214A July 1995 Processes Multiprocess Welding Description Semiautomatic Welding Platform Swingpak 12 & 16 Visit our website at www.MillerWelds.com From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you Miller is the first welding figure out what the problem is. The parts list equipment manufacturer in will then help you to decide which exact part the U.S.A. to be registered to the ISO 9001 Quality System you may need to fix the problem. Warranty and Standard. service information for your particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business. Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 SECTION 2 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 SECTION 3 – INSTALLATION OR RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 SECTION 4 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WARRANTY SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMATION AND SAFETY 1-2. A. General SAFETY ALERT SYMBOL AND SIGNAL WORDS The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instructions. Information presented in this manual and on various labels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment. This safety alert symbol is used with the signal words WARNING and CAUTION to call attention to the safety statements. WARNING statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life. B. Safety The installation, operation, maintenance, and troubleshooting of arc welding equipment requires practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with this manual and all safety precautions in the welding power source Owner’s Manual. CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment. IMPORTANT statements identify special instructions necessary for the most efficient operation of this equipment. SECTION 2 – SPECIFICATIONS Gas Cylinder Support Bracket Located Here (SWINGPAK-12 Models Only) Coolant System (Mounted Onto SWINGPAK Locker) Flux Tank *50-7/8 in. (1292 mm) Swingpak-12 Boom Support Base Welding Power Source C F E B L A Resistance Grid (Mounted Onto SWINGPAK Locker) Millimeters A 28 711 B 30 762 C 31 787 D 32-3/4 831 E 37 940 F 39 991 K G 14-1/2 368 G H 16-3/4 415 J 20 508 K 12-3/8 314 L 24-1/16 611 H J **65 in. (1651 mm) Swingpak-12 Inches D FRONT S-0458-A *66-7/8 in. (1699 mm) Swingpak-16 **79 in. (2007 mm) Swingpak-16 Figure 2-1. Overall Dimensions, Mounting Hole Layout, And Component Locations OM-1102 Page 1 2-1. DESCRIPTION Additional space is available on the base for mounting customer supplied accessories. The SWINGPAK-12 and SWINGPAK-16 provide a direct mounting facility for several welding power sources (refer to welding power source Owner’s Manual for base mounting hole layout), SWINGARC wire feeder or CB boom, RADIATOR 1A or RADIATOR 2A coolant system, MPG-395B resistance grid, AFT-100 flux tank, and shielding gas cylinder. If equipment other than that listed is to be used, mounting hole locations may have to be modified to accommodate equipment. A SWINGPAK locker and brackets for mounting a disconnect switch to the SWINGARC post support are also supplied. Table 2-1. Specifications Weight Net Ship SWINGPAK-12 412 lbs. (187 kg) 418 lbs. (190 kg) SWINGPAK-16 504 lbs. (229 kg) 510 lbs. (231 kg) SECTION 3 – INSTALLATION OR RELOCATION WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • 3-1. Disconnect equipment input power conductors from deenergized supply line BEFORE moving unit. LOCATION When installing this unit, be sure to allow room for the boom to swing horizontally in the desired arc, and to pivot upward to the desired angle. The location should allow room to remove panels of associated equipment for installation, inspection, maintenance, and repair procedures. Consider the input power requirements as well as coolant (water) needs of optional equipment when choosing a location. The service life and efficiency of this unit and associated equipment will be reduced if they are subjected to high levels of dust, dirt, moisture, corrosive vapors, and extreme heat. Mounting holes are provided in the SWINGPAK base for installing equipment. 3-2. IMPROPER LIFTING OR INSTALLING OF EQUIPMENT can cause personal injury and equipment damage. • Use equipment of adequate capacity to lift components. • Use bolts and fasteners of adequate capacity to assemble and install unit. IMPORTANT: Refer to Figures 2-1 and 4-1 during assembly as necessary. Mounting hardware is packed in locker for shipping purposes. Remove hardware kit from locker and proceed as follows: 1. Install boom support base onto SWINGPAK base using supplied 1/2-13 x 1-1/2 inch cap screws (Item 23, Figure 4-1) and associated hardware (see Figure 2-1 for mounting location). 2. Locate appropriate mounting holes on SWINGPAK base for welding power source, and install power source onto SWINGPAK base using supplied 3/8-16 x 1-1/4 inch cap screws (Item 20, Figure 4-1). 3. Install boom into boom support base following procedure outlined in appropriate Owner’s Manual. 4. If applicable, install AFT-100 flux tank onto SWINGPAK base using supplied 5/16-18 x 1 inch cap screws (Item 13, Figure 4-1) and associated hardware. 5. Install SWINGPAK locker onto SWINGPAK base using supplied 1/4-20 x 3/4 inch self-threading screws (item 16, Figure 4-1). 6. If applicable, install coolant system mounting brackets onto SWINGPAK locker using supplied 1/4-20 x 1inch cap screws (Item 7, Figure 4-1). INSTALLATION (Figures 2-1 And 4-1) WARNING: OVERTURNING BASE can result in serious injury and equipment damage. • Mount the welding power source on SWINGPAK base before mounting SWINGARC wire feeder into SWINGARC support base. • Do not install or operate on an incline. • Do not lift the SWINGPAK base with a fork lift from the sides unless the lift forks extend far enough under the base to ensure against tipping. OM-1102 Page 2 IMPORTANT: If cooling system has mounting holes in base, do not install mounting brackets onto SWINGPAK locker. Instead, install coolant system directly onto locker using supplied hardware. 7. If applicable, install grid onto SWINGPAK locker using supplied 1/4-20 x 1 inch cap screws (Item 7, Figure 4-1) and associated hardware. 8. If applicable, install gas cylinder support bracket onto SWINGPAK locker using supplied 5/16-18 x 3/4 inch self-threading screws (item 12, Figure 4-1). 9. Install cylinder support bracket to SWINGPAK locker using supplied 1/4-20 x 1 inch cap screws and associated hardware. Secure gas cylinder in bracket using supplied cylinder chain. 10. If applicable, install disconnect switch mounting brackets onto disconnect switch (customer must supply mounting hardware). WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Be sure input power is disconnected and welding power source is shut down before making connections to disconnect switch. 11. Install disconnect switch onto boom support, and secure using supplied disconnect switch mounting clamps (Item 2, Figure 4-1) and 3/8-16 nuts (Item 5) and associated hardware. 12. Make electrical input connections from welding power source to disconnect switch according to welding power source Owner’s Manual. 13. To make electrical connections from line disconnect switch to source of input power, consult local electric utility or certified electrician. OM-1102 Page 3 OM-1102 Page 4 Disconnect Switch 18 19 20 21 4 5 17 SWINGPAK Base Figure 4-1. Complete Assembly 3 16 7 15 Gas Bottle Support Bracket 6 9 SWINGPAK Locker 12 11 10 Cylinder Support Bracket 8 Coolant System Mounting Bracket 6 7 Gas Cylinder SD-113 627-A 14 13 AFT-100 Flux Tank RADIATOR 1 Or RADIATOR 2 Coolant System not available unless listed. 22 2 6 7 MPG-395B Resistance Grid . Hardware is common and 23 Boom Support Base 1 Disconnect Switch Mounting Brackets SWINGARC Digital Wire Feeder SECTION 4 – PARTS LIST Item No. Quantity Model Part No. Description 12 16 Figure 4-1. Complete Assembly .. 1 ... .. 2 ... .. 3 ... .. 4 ... .. 5 ... .. 6 ... .. 7 ... .. 8 ... .. 9 ... ........ . . 10 . . . . 11 . . . . 12 . . . . 13 . . . . 14 . . . . 15 . . . . 16 . . . . 17 . . . . 17 . . . . 18 . . . . 19 . . . . 20 . . . . 18 . . . . 19 . . . . 20 . . . . 21 . . . . 22 . . . . 23 . . 086 752 086 739 010 910 602 213 601 872 602 207 604 631 099 038 085 940 085 840 169 654 602 387 602 159 601 948 602 211 087 876 604 224 085 939 086 736 602 241 602 207 601 927 010 910 602 213 604 657 602 246 602 216 604 467 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. BRACKET, mtg disconnect switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 CLAMP, mtg disconnect switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 WASHER, flat SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8 WASHER, lock split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8 NUT, hex full .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8 WASHER, lock split .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . 10 SCREW, hexhd .250-20 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . 10 BRACKET, mtg coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 LOCKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 BRACKET, support tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 CHAIN, weldless 2/0 x 27 bright zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 SCREW, hexwhd .312-18 x .75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SCREW, hexhd-pln .312-18 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 WASHER, lock split .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 BRACKET, support gas bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SCREW, hexwhd .50D .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8 BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WASHER, flat stl SAE .250 (used w/Maxtron) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 WASHER, lock split .250 (used w/Maxtron) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 SCREW, cap stl hexhd .250-20 x .750 (used w/Maxtron) . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 WASHER, flat SAE .375 (all models except Maxtron 450) . . . . . . . . . . . . . . . . . . . . 4 . . . 4 WASHER, lock split .375 (all models except Maxtron 450) . . . . . . . . . . . . . . . . . . . . 4 . . . 4 SCREW, hexhd-pln .375-16 x 1.250 (all models except Maxtron 450) . . . . . . . . . . 4 . . . 4 WASHER, flat .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 WASHER, lock split .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 SCREW, hexhd-pln .500-13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1102 Page 5 Notes Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. * LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts – 3 Years Labor * * 2. 3 Years — Parts and Labor * * * * * * 3. Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year — Parts and Labor * * * * * * * * * * * * * * * * * DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate 185 & Spoolmate 250) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) 4. 6 Months — Batteries 5. 90 Days — Parts * * MIG Guns/TIG Torches Induction Heating Coils and Blankets * * * * * APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate 185 & Spoolmate 250 Canvas Covers Miller’s True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. 2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. 3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller_warr 7/00 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Technical Manuals (Servicing Information and Parts) Circuit Diagrams European Headquarters – United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 Welding Process Handbooks www.MillerWelds.com Contact the Delivering Carrier for: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00